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    A mathematical approach of evaluating sustainability indicators in milling of aluminium hybrid composite by different eco-friendly cooling strategies
    (Elsevier, 2023) Sivalingam, Vinothkumar; Zhou, Qian; Selvam, Baskaran; Sun, Jie; Pandiyan, Karthik; Gupta, M. K.; Korkmaz, Mehmet Erdi
    The purpose of this study is to evaluate the sustainability indicators of aluminium hybrid composite material (AA6082 + 3wt%SiC+1wt .%MoS2) under different eco-friendly cooling strategies such as dry, MQL, LCO2, MQL + LCO2. A variety of social, economic, and environmental aspects of sustainability indicators such as Total cycle time (TTCT), productivity, Total machining cost (CT) Energy consumption (Ec), Carbon emission analysis (Cee), Cutting force (CF) and Surface Roughness (Ra) are considered in this study. A novel sustainable approach of overall equipment effectiveness (OEE) is included to evaluate the true productivity under different cooling en-vironments. By comparing all the machining conditions, it was found that hybrid (CO2 + MQL) resulted the highest OEE as 95.63% and very low carbon emission of 0.6 kg-CO2 under higher cutting speed of 120 m/min and feed rate of 0.1 mm/rev at 1 mm depth of cut.
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    Understanding the machining characteristics of Al6082 hybrid metal matrix composites milled under cryogenic cooling conditions
    (Springer London Ltd, 2023) Sivalingam, Vinothkumar; Zhou, Qian; Manickajothi, Ganesh; Ross, Nimel Sworna; Sun, Jie; Gupta, Munish Kumar; Korkmaz, Mehmet Erdi
    Cutting fluid used in machining is under investigation to check the achievement of sustainability and the cleaner process by the machining process. Many attempts were made to find new cooling strategies as an alternative to the existing cooling methods. Cryogenic cooling was an efficient method to move towards sustainability for machining any materials and to ensure green machining. Machining of Al6082 HMMC has been carried out under distinct cutting environments. The fallout of these cutting environments was studied based on parameters like surface roughness, cutting temperature, chip morphology, and tool wear. The application of cryogenic CO2 substantially reduced the tool wear by 37% and 48% when compared to MQL and wet conditions. The SEM image of the worn tool disclosed that adopting the cryogenic cooling technique led to less crater wear and prevented the peeling of the tool layer to some extent. The impressive cooling effect of cryogenic cooling also produced a good surface finish on the machined surface compared to the other cooling environments. Thus, cryogenic cooling proved to be trustworthy in all the output parameters.
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    Understanding the machining induced tribological mechanism of Hastelloy-X under sustainable cooling/lubrication conditions
    (Springer London Ltd, 2022) Zhou, Qian; Sivalingam, Vinothkumar; Sun, Jie; Murugasen, Pradeep Kumar; Gupta, Munish Kumar; Korkmaz, Mehmet Erdi
    Despite the recent developments in non-conventional manufacturing approaches, machining is still a prominent technique for the mass production of metallic components. However, given the difficult-to-machine nature and high heat generation during machining of Hastelloy-X, there is a lack of comparative investigations that can provide basics for sustainable process management in machining of Hastelloy-X. Different sustainable cooling approaches (dry, minimum quantity lubrication (MQL), cryogenic) and their impact on Hastelloy-X machining process behavior have been investigated in this study. Machining parameters such as constant cutting speed of 124 mm/min, feed rate of 0.15 mm/min, and cutting depth of 0.1 mm and cutting force, cutting temperature, and surface roughness were consider as output responses. It was observed that with the adaptation of cryogenic conditions, cutting forces can be reduced 5 to 14% in comparison with MQL and dry conditions. Cutting temperature and surface roughness values were however observed to be largely reduced with cryogenic cooling. The chipping and adhesion were found to be reduced with cryogenic cooling due to the reduction in workpiece softening behavior and increase in hardness to cutting tool.